This content is not included in
your SAE MOBILUS subscription, or you are not logged in.
Computation of Fatigue Safety Factors for High-Pressure Die Cast (HPDC) Aluminum Components Taking into Account the Pore Size Distribution
Technical Paper
2009-01-0082
ISSN: 0148-7191, e-ISSN: 2688-3627
Annotation ability available
Sector:
Language:
English
Abstract
Aluminum high-pressure die casting (HPDC) is used to reduce the cost and weight of various components in the automotive industry. The main problem with HPDC components is related to inherent flaws (porosity, oxide skins, etc.) that are difficult to avoid.
The fatigue of aluminum HPDC parts is typically calculated using two S–N curves; one accounts for flaws in the bulk material and the other for the pore-free surface layer. This does not provide an accurate estimate for computation of the lifetime or safety against failure of the component.
This paper presents a unique way to compute the fatigue safety factor taking into account the pore distribution of the component. The material model used is the so-called Kitagawa-Haigh diagram.
The pore model provides a statistical distribution of pores within a defined region in the component. Multiple runs with a defined random pore distribution are used to compute the fatigue safety factor utilizing the statistical pore distribution of the pore model proposed here for different regions in the component.
Recommended Content
Authors
Citation
Oberwinkler, C., Leitner, H., and Eichlseder, W., "Computation of Fatigue Safety Factors for High-Pressure Die Cast (HPDC) Aluminum Components Taking into Account the Pore Size Distribution," SAE Technical Paper 2009-01-0082, 2009, https://doi.org/10.4271/2009-01-0082.Also In
References
- Aichberger, W. Riener, H. Dannbauer: H. “Regarding influences of production processes on material parameters in fatigue life prediction”” SAE 2007 World Congress Detroit, SAE, paper, 2007-17-1650 2007
- Ting, J.C. Lawrence: F.V. “Modeling the long-life fatigue behavior of a cast aluminium” Fatigue and Fracture of Engineering Materials and Structures 16 631 647 1993
- Ammar, H.R. Samuel, A.M. Samuel: F.H. ”Porosity and the fatigue behavior of hypoeutectic and hypereutectic aluminum-silicon casting alloys” International Journal of Fatigue 30 1024 1035 2008
- Couper, M.J. Neeson, A.E. Griffiths: J.R. “Casting defects and the fatigue behaviour of an aluminium casting alloy” Fatigue and Fracture of Engineering Materials and Structures 13 213 227 1990
- Kitagawa, H. Takahashi: S. ”Applicability of fracture mechanics to very small cracks or the cracks in the early stage” in: Proceedings of the 2nd International Conference on Mechanical Behaviour of Materials, ASM 627 631 1976
- Murakami, Y. Endo: M. ”The parameter model for small defects and non-metallic inclusions in fatigue strength: experimental evidence and applications” in: Theoretical Concepts and Numerical Analysis of Fatigue, EMAS Ltd 51 71 1992
- Klein, F. Plattenhardt: F. “Influence of die filling on the density and volume of pressure die castings” Giessereiforschung 45 115 124 1993
- Roy, N. Samuel, A.M. Samuel: F.H. “Porosity formation in Al-9 Wt Pct Si-3 Wt Pct Cu alloy systems: metallographic observations” Metallurgical and Materials Transactions 27 415 429 1996
- Entwistle, R.A. Gruzleski, J.E. Thomas: P.M. “Development of porosity in aluminium-base alloys”, in” Solidification and Casting of Materials, The Metals Society 345 349 1979
- Samuel, A.M. Samuel: F.H. “Porosity factor in quality aluminium castings” AFS Transactions 100 657 666 1992
- Conley, J.G. Huang, J. Asada, J. Akiba: K. “Modelling the effects of cooling rate, hydrogen content, grain refiner and modifier on microporosity formation in Al A356 alloys” Materials Science and Engineering 285 49 55 2000
- Atwood, R.C. Lee: P.D. “Simulation of the three-dimensional morphology of solidification porosity in an aluminium–silicon alloy” Acta Materialia 51 5447 5466 2003